a value added opportunity for wood handlers
Post on 30-May-2022
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A Value Added Opportunity for Wood Handlers
Adam K. Downing, Extension AgentForestry & Natural Resources, Northern Piedmont Area
…Sales of lump charcoal have more than quadrupled in the past 7 years and more than doubled since 1998. About 91,000 tons were sold in 2002, up 9.64% from the year before. While lump charcoal still accounts only for about one-tenth the amount of traditional pillow-shaped briquettes sold annually, it is definitely an exciting trend for lump processors…
USDA Forest Service, June 2003, Forest Products Conservation & Recycling Review
Market Niche for Lump Coal
Outline
• History• How To• Economics
• Marketing• Considerations
– legal
Three Forms (Pyramid, Sphere, Cube) David Nash, Artist
Briquetts VS. Real (lump/natural)
Briquetts• Orin F. Stafford &
Henry Ford• Sawdust & stuff
– Binders (starch)– Paraffin or petroleum– Limestone to color ash
Real• Since fire was
discovered• Charred wood
Charcoal HistoryUS pig-iron Industry
• An average furnace would consume from 600-800 bushels of charcoal every 24 hours. This required about 30-40 cords of wood from trees 25-30 years old.
• 8 cords of wood to for one ton of pig iron.
• One iron season (summer) would consume 4,428 cords of wood a year– 150 acres of woodlands each year. – 5 furnaces in Massanutten area >
750 acres/year.– In a 30 year “cycle” 19,000 and
23,000 acres of forest had been clear-cut in continuous bands.
Back in the day…
Today
Two methods: Indirect and Direct• Indirect: “cook” the wood with an external
fuel and “reburn” (retort) the gases.– Less skill required, higher yield, less smoke
• Direct: heat is direct from the fuel being charred. Can also retort to reduce smoke.– The original method– Less complicated kiln– Low oxygen burn, controlled oxygen
Portable metal kilns
• Ancient technology “mastered” in 1930s
Portable metal kilnsModern version
(modified New-Hampshire style kiln)
Portable metal kilns: Fabrication• Specifications/goals
– Portable – transport on full size pickup
– Inexpensive – materials cost under $500 - $1000
– Minimal – tools/skill/time needed for fabrication
Kiln operation• 48-72 hours production time
– Unattended overnight / low maint. daytime– One person operation during most of production
• Nontechnical– Load, light, and “leave it alone”
• Safe– Minimal fire hazard, risk to operator, loss of product,
etc.• Ideal for multiple kiln operation
– One-half to two-thirds cord of wood per batch– Yields 200 – 300 lb marketable charcoal
Photo-torial
Air-dry wood
Kindling in the middle
Load it, tight
Seal it
• Caulking (high temp)• Sand• Dirt• Foil tape
Light it Add stacks
“Burn” the volatiles, reduce oxygen, watch the smoke
After ~ 20 hrs
• Close• Seal every air gap• Let it sit for at least 24
hours.– 48 hrs. better
• Be sure it’s cool before opening
Take off the top
Sorting
Product: The best darned BBQ fuel
Rules for making charcoal:from Gary Gilmore, PA-DCNR Forester
1. Don’t waste your time using green wood. GREEN WOODMAKES LOTS OF SMOKE AND VERY LITTLE CHARCOAL!
2. Don’t aggravate your neighbors by smoking them out. Use an afterburner or go somewhere where no one will mind the smoke.
3. Don’t use treated or painted wood for charcoal if you are going cook with it. Chemicals will remain in the charcoal and WILL poison you.
4. Don’t put freshly made charcoal in a container that will burn or in a building that could burn.
5. Don’t try this inside!!!! 6. If you don’t have enough common sense to be careful with
fire and you want to blame me for your mistakes, DON’T make charcoal. Go play a game of golf or watch TV.
http://www.puffergas.com/terra/rules/rules.html
Puffergas…
Product: Natural Hardwood Charcoal
• 90% pure carbon (moisture, ash, volatiles)• No petroleum additives, binders, or
fillers– add more under grilling food without
unwanted “starter fluid taste”• “Reusable” (easily extinguished when covered)
• Imparts excellent flavor and aroma to foods
How to use it
• Use a “chimney” to light charcoal• Lights fast (5-10 min)• Burns clean, hot, long (600°, 25-
45 minutes)• Can add more charcoal directly• Sensitive to oxygen• Low ash build-up
Economics - “Black Gold?”
• Cost of raw material = $0.00– Stuff that’s not even good for firewood
• Think of this as a down-time filler– Great winter work
• Sell firewood & charcoal
Cost worksheet.xls
Firewood Comparison
Kiln ~ $2000.00Bag closer ~ $400.00Other materials ~ $30.00
Additional costs = delivery, drying time, saw, splitter, etc.
“Profit” ~ $84 (180%)“Profit” ~ $45 (150%)
Costs: Labor & bags~$150.00 (13 hrs. + bags)
Costs: labor~ 3 hrs. ?($30.00)
Value as charcoal ~ $234.00 bagged
Sells for ~ $75.00cut, dried and stacked
Figuring ½ cord of firewood (2’x4’x8’)
Other angles
• Do you pay to get rid of wood?• Retail value of 1 ton charcoal = $1000• Firewood delivered 1 ton = $60• Charcoal is about ¼ the weight
Marketing Ideas
• Farmers Markets: Local Fuel for Local Food– Local markets & brands
• Tailgaters• BBQ events• Demos at festivals• Bulk to restaurants & caterers
• Applying for
Additional Considerations
• Legal– Burning ordinances– Bring waste wood “home”
• Waste– Fines… are they waste or “bio-char”?
• Smoke
Smoke
• A big deal depending where you are– May not be permissible without permit in
some areas– Reduce smoke with catalytic converter– Be considerate of neighbors– EPA research shows charcoal making smoke
less polluting than open burning.• Check with authorities• http://www.deq.state.va.us/air/regulations/airregs.html
Work in Progress
• Cost Revenue Analysis• Bio-char utilization• Emission-free operation
– Catalytic conversion– After-burners
• New producer support– Kiln loan
Acknowledgements
• Virginia DOF – Charlie Becker• Virginia Tech Forestry – Phil Radke• New River-Highlands Resource,
Conservation and Development Area – Dave Richert
• USDA Forest Service
Are you Green Grillin’?www.forestry.vt.edu/charcoal
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